Study on the forming process of thread raceway surface under the hard whirling

Compared with traditional hard cutting technology, the thread whirling has features of multi-DOF coupling motions and incremental forming with multi-tools. In order to analyze the forming process of thread whirling and obtain the scallop height on cutting surface, considering the specialties of thread whirling technology and thread raceway shape, the two-dimensional theoretical model of scallop height was established, and the simulation program of processing track was designed based on the API of Solidworks. Then the effect on the thread raceway surface quality applying different values of whirling parameters, such as the diameter of the cutter head, the rotate speed, the number of cutter-tools, was studied, which would be useful to predict the roughness of thread raceway. Meanwhile, the thread hard-whirling FEA model was set up by "Deform 3D" in order to simulate chip shape, which is also helpful to study the thread hard whirling mechanism. In the end, the whirling experiment on large-scale thread was carried out, which testified the FEA model validity through comparing the chip shape. These results can be used to improve the processing precision of thread raceway and the processing efficiency of hard whirling.